1999 Opel Astra Van engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


Lower section of intake manifold	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.
Upper section of intake manifold	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m


All other modifications	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreIntake manifold support


On intake manifold	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Support on cylinder head	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt deflection pulley


2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1999.1–2005.4)	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreAuxiliary drive belt tensioner

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


Adjusting screws	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Otherwise	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m


All Opel diesel straight-4 2.0 L X 20 DTL engines	30.98 lbf⋅ft30.98 lbf⋅ft42 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAir-conditioning compressor


All Opel diesel straight-4 1.7 L X 17 DTL engines	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
All Opel diesel straight-4 2.0 L X 20 DTL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAir-conditioning compressor bracket


All Opel diesel straight-4 1.7 L X 17 DTL engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m


Air-conditioning compressor pressure line	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAlternator

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


Bottom	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Top	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m


All Opel diesel straight-4 2.0 L X 20 DTL engines	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreGenerator bracket


All Opel diesel straight-4 1.7 L X 17 DTL engines	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreVacuum pump


1.7 TD with diesel straight-4 1.7 L 67 HP at 4500 RPM, 132 N⋅m at 2400 RPM engine (1999.1–2005.4)	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m

expand_moreCarburetion

expand_moreExhaust gas return valve


1.6 with gasoline straight-4 1.6 L 74 HP at 5200 RPM, 128 N⋅m at 2800 RPM engine (1999.1–2000.9)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


Fuel-distributing pipe	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m

expand_moreInjection hoses


All Opel diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 2.0 L X 20 DTL engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreInjection nozzle (injector)


All Opel diesel straight-4 1.7 L X 17 DTL engines	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


First stage	hand-screwed
Second stage	360°360°360°


Injection pump	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection pump pulley


All Opel diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreCharging

expand_moreCharge air pipes

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


Clamps	2.58 lbf⋅ft2.58 lbf⋅ft3.5 N⋅m

expand_moreTurbo charger


All Opel diesel straight-4 1.7 L X 17 DTL engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreTurbocharger oil feed line

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


At the turbocharger	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
On the engine block	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreTurbocharger oil return line

expand_more1.7 TD with diesel straight-4 1.7 L 67 HP at 4500 RPM, 132 N⋅m at 2400 RPM engine (1999.1–2005.4)


At the turbocharger	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCooling system

expand_moreCoolant drain plug


Coolant pump	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCoolant pump


All Opel diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 2.0 L X 20 DTL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCoolant pump pulley


All Opel diesel straight-4 2.0 L X 20 DTL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFan wheel


1.7 TD with diesel straight-4 1.7 L 67 HP at 4500 RPM, 132 N⋅m at 2400 RPM engine (1999.1–2005.4)	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m

expand_moreRadiator mounting


Bottom	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Opel diesel straight-4 2.0 L X 20 DTL engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCylinder head screws

expand_moreAll Opel gasoline straight-4 1.6 L X 16 SZR engines

Figure 1. Cylinder head, Cylinder head screws, Opel gasoline straight-4 1.6 L X 16 SZR.


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Use new screws. See figure 1.
Second stage	60°60°60°
Third stage	60°60°60°
Fourth stage	60°60°60°

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Use new screws
Second stage	90°90°90°
Third stage	90°90°90°
Fourth stage	45°45°45°
Fifth stage	Test run
Sixth stage	30°30°30°
Seventh stage	15°15°15°

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Use new screws. See figure 1.
Second stage	65°65°65°
Third stage	65°65°65°
Fourth stage	65°65°65°
Fifth stage	65°65°65°
Sixth stage	15°15°15°

expand_moreValve cover


All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


First stage	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreAll other modifications


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws and nuts.
Second stage	30°30°30°

expand_moreCrankcase ventilation


Crankcase ventilation pipe	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Use new seals.

expand_moreCrankshaft central screws

expand_moreAll Opel gasoline straight-4 1.6 L X 16 SZR engines


First stage	70.07 lbf⋅ft70.07 lbf⋅ft95 N⋅m
Replace screws.
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


First stage	95.88 lbf⋅ft95.88 lbf⋅ft130 N⋅m
Use new screw.
Second stage	40–50°40–50°40–50°

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


First stage	110.63 lbf⋅ft110.63 lbf⋅ft150 N⋅m
Replace screws and nuts.
Second stage	45°45°45°
Third stage	15°15°15°


Crankshaft pulley	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFlywheel

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


First stage	47.94 lbf⋅ft47.94 lbf⋅ft65 N⋅m
Replace screws and nuts.
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


First stage	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace screws.
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreAll other modifications


First stage	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreMain bearing

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws and nuts.
Second stage	60°60°60°
Third stage	15°15°15°

expand_moreAll other modifications


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws and nuts.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreEngine control

expand_moreCamshaft timing chain guide rail


2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1999.1–2005.4)	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCamshaft timing chain tensioning rail


2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1999.1–2005.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCamshaft timing gear

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


First stage	55.32 lbf⋅ft55.32 lbf⋅ft75 N⋅m
Replace screws.
Second stage	60–65°60–65°60–65°

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws and nuts.
Second stage	60°60°60°
Third stage	30°30°30°


All other modifications	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreChain tensioner locking screws


2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1999.1–2005.4)	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreTiming case cover


2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1999.1–2005.4)	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreToothed belt guard at the bottom


All Opel gasoline straight-4 1.6 L X 16 SZR engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m
All Opel diesel straight-4 1.7 L X 17 DTL engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m

expand_moreToothed belt guard at the top


All Opel gasoline straight-4 1.6 L X 16 SZR engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m
All Opel diesel straight-4 1.7 L X 17 DTL engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m

expand_moreToothed belt tensioning roller


All Opel gasoline straight-4 1.6 L X 16 SZR engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Opel diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreEngine lubrication

expand_moreOil cooler


All Opel diesel straight-4 1.7 L X 17 DTL engines	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m

expand_moreOil cooler lines


1.7 TD with diesel straight-4 1.7 L 67 HP at 4500 RPM, 132 N⋅m at 2400 RPM engine (1999.1–2005.4)	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreOil drain plug


All Opel gasoline straight-4 1.6 L X 16 SZR engines	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


One-part sump	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Two-part oil sump	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m


All Opel diesel straight-4 2.0 L X 20 DTL engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreOil filter


All Opel gasoline straight-4 1.6 L X 16 SZR engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Slightly oil sealing lips.
All Opel diesel straight-4 1.7 L X 17 DTL engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOil filter housing


All Opel diesel straight-4 2.0 L X 20 DTL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOil lines

expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1999.1–2005.4)


At the turbocharger	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOil pressure sensor


All Opel gasoline straight-4 1.6 L X 16 SZR engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
All Opel diesel straight-4 1.7 L X 17 DTL engines	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreOil pump


All Opel diesel straight-4 1.7 L X 17 DTL engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All Opel diesel straight-4 2.0 L X 20 DTL engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All other modifications	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreOil sump


All Opel gasoline straight-4 1.6 L X 16 SZR engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Clean the thread and use screw-locking compound.

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines

expand_moreAt the gearbox


Oil sump top part	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreOil sump lower part


First stage	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
Second stage	30°30°30°

expand_moreOn the engine block


Oil sump top part	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


One-part sump	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines

expand_moreAt the gearbox


M10	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M8	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m


On the engine block	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreEngine management

expand_moreCrankshaft sensor


All Opel gasoline straight-4 1.6 L X 16 SZR engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All other modifications	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreGlow plugs


All Opel diesel straight-4 1.7 L X 17 DTL engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Opel diesel straight-4 2.0 L X 20 DTL engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m

expand_moreKnock sensor


All Opel gasoline straight-4 1.6 L X 16 SZR engines	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m

expand_moreLambda sensor


All Opel gasoline straight-4 1.6 L X 16 SZR engines	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreEngine mounting

expand_moreEngine bracket


All Opel diesel straight-4 1.7 L X 17 DTL engines	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreAll Opel diesel straight-4 2.0 L X 20 DTL engines


On engine mounting	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m

expand_moreEngine mounting

expand_moreAll Opel gasoline straight-4 1.6 L X 16 SZR engines


On chassis	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Replace screws.
On the engine block	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Replace screws.


All Opel diesel straight-4 1.7 L X 17 DTL engines	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreSubframe


First stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m
Replace screws.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreExhaust system

expand_moreCatalytic converter


All Opel diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreExhaust manifold


All other modifications	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.

expand_moreExhaust manifold heat shields


All Opel gasoline straight-4 1.6 L X 16 SZR engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
All Opel diesel straight-4 1.7 L X 17 DTL engines	7.38–8.85 lbf⋅ft7.38–8.85 lbf⋅ft10–12 N⋅m

expand_moreExhaust pipe

expand_moreAll Opel gasoline straight-4 1.6 L X 16 SZR engines


Collar screws	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Nuts	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


All Opel diesel straight-4 1.7 L X 17 DTL engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreExhaust pipe rear


All Opel gasoline straight-4 1.6 L X 16 SZR engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Opel diesel straight-4 1.7 L X 17 DTL engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreFuel supply


Fuel filter housing	4.43 lbf⋅ft4.43 lbf⋅ft6 N⋅m

expand_moreIgnition system


Spark plugs	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreStart system

expand_moreStarter

expand_moreAll Opel diesel straight-4 1.7 L X 17 DTL engines


At the gearbox	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
On the engine block	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m


All Opel diesel straight-4 2.0 L X 20 DTL engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 1999 Opel Astra Van user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Opel warranty policy for your region. In some regions DIY service may invalidate your warranty.

Maintenance Items

Chassis and Body Fastener Tightening Specifications
Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Opel Astra Van service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 1999 Opel Astra Van you're not only saving money, but also also improving your technical skills and learning something new.

1999 Opel Astra Van generations

In 1999 Opel offered 2 generations of the Astra Van. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

F facelift

T Platform (T-body, GM2700, GM3000) 1979-2012

1999 Opel Astra Van G Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

1999 Opel Astra Van generations

F facelift

Opel Astra Van G model years

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